SLA (Stereolithography Apparatus)

• Direct digital manufacturing of Ford GT key fobs using high resolution SLA
• Bought the assets of Genieo Prototype and installed Viper Stereolithography system in our show room as a demonstrator model and for use in servicing our prototyping customers
• Conserved over 50% of projected cost by making Boeing 787 Flight Controls : Throttle, Flap, Reverse & Disconnect  lever including mirrored parts for 2 flight simulators, which were delivered in one week
• Made 21 piece prototype of cutlery set for design confirmation models
• Converted CT scan of TMJ condoyle and made SLA model master to cast replacement
• Prototyped flight simulator knobs and handle directly from RP materials to eliminate the need for urethane cast parts
• Next day delivery of prototypes for housing components of fresh Blue Tooth device
• Presented 93 piece SLA order for assembly confirmation to reduce tool changes
• Delivered full scale SLA model of car seat for children with Cerebral Palsy. The model was completed in one week
• Shipped a 302 piece SLA order in one week! Used both 14120 white and SI 60 Clear material. Parts were finished and painted and were displayed at a trade show since molds from Asia were later or inaccurate
• Utilized SLA to prototype new characters for animated children’s TV show
• Created SLA scaled architectural models for multiple designs
• Generated a prototype of hollow handle BBQ tongs in 316 Stainless Steel assembly with spring back lock mechanism in SLS and handles in SLA
• Fabricated 3 SLA buildings for architectural presentation and design competition in U.A.E.

SLS (Selective Laser Sintering)

• Delivered 3 sets of 1/20 scale models of a people mover made in SLS Glass Filled Nylon
• Direct digital manufacturing of 24 sets of electronic enclosures in SLS Nylon – painted black
• Used SLS sintered Nylon, sealed with super glue, to make a “breast phantom” for use in calibrating 3 MRI machines across Canada to produce consistent research results
• Manufactured large personalized luggage tags for a synchronized skate team at a cost of $10 each
• Provided overflow SLS production capacity to one of the world’s largest Rapid Prototyping service bureaus
• 30 Pieces of a large electronic enclosure in one week, for $24,000
• Accomplished follow on order of Handyscan3D ExcaScan housings in SLS. This model was used for a world-wide launch
• Constructed SLS heat Exchanger to withstand 400 degree F & 120 psi
• Manufactured 28 part, 41 piece mock-up of helicopter assembly from Z Corp and SLS materials in 2 weeks
• Distributed 165 piece SLS order of same parts for 3 sets of functional test and sales models
• Directly constructed Therapy System using SLS nylon
• Implemented SLS high elongation nylon to produce flight test components
• Concocted 198 pieces in SLS Nylon for proving out assembly automation machine
• Produced a custom cleaning rod for drinking water treatment in house

Machine Sales

• Produced sales marketing engineering samples from commercial roll-out of new industrial product
• Sold Projet HD-3000 3D printer to Ontario College of Art and Design
• Sold SLA Viper to industrial client
• Pre-sold multiple V-Flash 3D printers
• Sold stereolithography (SLA) machine
• Sold 3D Systems Sinterstation HiQ SLS machine to 1^st time equipment buyer
• Sold 3D Systems Invision LD 3D printer to educational institution. Printer was delivered and installed two weeks after receipt of order
• Sold Invision LD 3D Printer to Automotive Technical Centre
• Installed SLA 3500 RP machine at customer site
• Began supplying SLA & SLS raw materials to local RP machine users, including the National Research Council

Scanning

• Scanned hydro turbine runner blades and throat ring for reverse engineering repair patches
• Scanned damaged area on a water turbine runner blade to reverse engineer patch for weld repair. Data was captured 100% in 1/10^th of the time of CMM process
• Scanned corroded steel pipe to CNC Corrosion Inspection gauge with SLS made highly accurate (=/- .004”) production fixtures for automated assembly machine of car vents

MJM (Multi Jet Modeling)

• Machines finely detailed fluid spray prototypes

DMLS (Direct Metal Laser Sintering)

• Direct Metal Chess set.
• Employed SLS metal prototypes for the new Hot Runner System
• Distributed Direct Metal Laser Sintered (DMLS) 4 part mold, finished and fitted for over-molding tiny components

Cast Urethanes

• Made mold for silicone gasket using high resolution stereolithography
• Made 4 large SLA masters, 4 silicone rubber molds and 5 sets pf cast urethane chair parts for trade show models
• Released 50 sets of rigid urethane foam computer covers 4 weeks after receipt of order, for touch screen Kanban MRP system for major automotive supplier. Materials used include: SLA Masters, Rigid Epoxy tooling, rigid foam castings and textured paint finish

Rapid Metal Casting

• Created production-lie AL cast parts in 5 weeks using: SLA masters, Epoxy Wax Dies, Investment Castings, finish machining and polishing. We also made Other Arms, Legs, End Cap (SLS) and Mounts for 7 units
• Delivered initial 8 sets of two Military Cockpit Display components – 7 parts in all: 4 Machines, 3 Investment Cast and finished  machined including: multiple thread inserts, studs, chromate, and MIL spec paint. Order was completed in 6 weeks. Executed delivery of 30 Chassis Units and 45 Housing units before Dec 31! Wax dies were unnecessary.

CNC Machining

• Three sets of Machined EPS foam toy prototypes were delivered in under one week
• Machined MDF Masters for use in casting rigid epoxy seat foam tools, which were delivered in one week

Vacuum / Thermo Forming

• Designed a new Vending Machine Cover. Manufactured the MDF prototype vacuum form mold

Reverse Engineering

• Reverse Engineered: Carbon Fiber Bike Fork, Vacuum Cleaner Bucket, and Van Door Handle Exterior Trim from comparison to and confirmation of replacement parts designs and tooling
• Reverse Engineered gear for photo finishing machines manufactured 20 units for replacement parts using SLS nylon eliminating need for replacement injection mold

Inspection

CAD Verification

Tool Archiving

Historic Preservation

CAD (Computer Aided Design)

• Re-designed SUV cabin air outlet in Catia v5 for improved fit and finish based on customer’s point data from mock-up with new edge and mounting locations, prototyped via SLA to confirm design: delivered both new design and prototypes in less than two weeks

Composites (Carbon Fiber, Fiberglass, etc.)

• Supplied fiberglass enclosure for a new medical diagnostic machine